WO2022164869A1 - Charge d'alimentation de fil plaqué pour la fabrication additive par dépôt d'énergie dirigée - Google Patents

Charge d'alimentation de fil plaqué pour la fabrication additive par dépôt d'énergie dirigée Download PDF

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Publication number
WO2022164869A1
WO2022164869A1 PCT/US2022/013856 US2022013856W WO2022164869A1 WO 2022164869 A1 WO2022164869 A1 WO 2022164869A1 US 2022013856 W US2022013856 W US 2022013856W WO 2022164869 A1 WO2022164869 A1 WO 2022164869A1
Authority
WO
WIPO (PCT)
Prior art keywords
clad
wire feedstock
core material
constructed
clad wire
Prior art date
Application number
PCT/US2022/013856
Other languages
English (en)
Inventor
Charles Brandon SWEENEY
Original Assignee
Essentium, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Essentium, Inc. filed Critical Essentium, Inc.
Priority to EP22746510.1A priority Critical patent/EP4274700A1/fr
Publication of WO2022164869A1 publication Critical patent/WO2022164869A1/fr
Priority to US18/359,422 priority patent/US20230415267A1/en

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/02—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
    • B23K35/0222—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape for use in soldering, brazing
    • B23K35/0227—Rods, wires
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K10/00—Welding or cutting by means of a plasma
    • B23K10/02—Plasma welding
    • B23K10/027—Welding for purposes other than joining, e.g. build-up welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K15/00—Electron-beam welding or cutting
    • B23K15/0046—Welding
    • B23K15/0086—Welding welding for purposes other than joining, e.g. built-up welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/34—Laser welding for purposes other than joining
    • B23K26/342—Build-up welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/02—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
    • B23K35/0255—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape for use in welding
    • B23K35/0261—Rods, electrodes, wires
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/28—Selection of soldering or welding materials proper with the principal constituent melting at less than 950 degrees C
    • B23K35/286—Al as the principal constituent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y70/00—Materials specially adapted for additive manufacturing
    • B33Y70/10—Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y70/00—Materials specially adapted for additive manufacturing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • the present disclosure is directed to a clad wire feedstock for directed energy deposition (DED) additive manufacturing.
  • DED directed energy deposition
  • Directed energy deposition refers to a category of additive manufacturing or three-dimensional printing techniques that involve a feed of powder or wire that is melted by a focused energy source to form a melted or sintered layer on a substrate.
  • the focused energy source is usually a laser beam, a plasma arc or an electron beam may be used instead.
  • Current wire-based DED systems employ filament wires that are composed of a single metal or alloy composition. However, employing a filament wire that is composed of a single metal or alloy results in a printed part that is homogenous in composition and structure. [0005]
  • current filament wires used in additive manufacturing techniques achieve their intended purpose, there is a need for new and improved filament wires used in DED processes.
  • a coaxial clad wire feedstock for directed energy deposition (DED) additive manufacturing is disclosed.
  • the clad wire feedstock includes a core material defining an outer surface and one or more clad metal layers that surround the outer surface of the core material.
  • a method for creating an article by a DED process includes melting, by a focused energy beam, a clad wire feedstock.
  • the method also includes depositing the clad wire feedstock onto a substrate that is part of a three-dimensional printer, where the clad wire feedstock includes a core material defining an outer surface and one or more clad metal layers that surround the outer surface of the core material.
  • FIG. 1 is a schematic diagram of a three-dimensional printer used in a DED process, where the three-dimensional printer employs the disclosed clad wire feedstock;
  • FIG. 2 is a cross-sectioned view of clad wire feedstock shown in FIG. 1 , where the clad wire feedstock includes a clad metal layer and a core material;
  • FIG. 3 is an enlarged, cross-sectioned view of the article shown in FIG. 1 , taken along section line A-A;
  • FIG. 4 is a cross-sectioned view of another embodiment of the clad wire feedstock where the clad metal layer is constructed of a brazing alloy;
  • FIG. 5 is a cross-sectioned view of yet another embodiment of the clad wire feedstock where the clad metal layer 242 is constructed of a grain boundary inhibitor;
  • FIG. 6 is a cross-sectioned view of still another embodiment of the clad wire feedstock where the clad metal layer is constructed of a material that is relatively ductile;
  • FIG. 7 is a cross-sectioned view of another embodiment of the clad wire feedstock where the clad metal layer acts as an optical energy absorber;
  • FIG. 8 is a cross-sectioned view of another embodiment of the clad wire feedstock having two or more clad metal layers.
  • FIG. 9 is a cross-sectioned view of another embodiment of the clad wire feedstock having multiple layers.
  • the present disclosure is directed to a clad wire feedstock used in a directed energy deposition (DED) process.
  • DED directed energy deposition
  • FIG. 1 a three-dimensional printer 10 for creating an article 12 based on the DED process is illustrated.
  • the three-dimensional printer 10 includes a substrate 20 for providing support to the article 12, an arm 24, a nozzle 26 configured to deposit a build material 28, and an energy source 32.
  • the build material 28 is in the form of a clad wire feedstock 36.
  • the clad wire feedstock 36 is a cross-sectioned view of the clad wire feedstock 36, which is constructed of two or more dissimilar materials.
  • the clad wire feedstock 36 includes a core material 40 and one or more clad metal layers 42 that extend coaxially and coat an outer surface 44 of the core material 40.
  • the core material 40 may be any type of metal employed in a DED process and is selected based on the specific application. Referring to both FIGS. 1 and 2, the clad wire feedstock 36 is fed to the nozzle 26, where the nozzle 26 is mounted to the arm 24, which may be a multi-axis arm having four, five, or six axes.
  • a focused energy beam 48 generated by the energy source 32 melts the clad wire feedstock 36 onto either a build surface 50 of the substrate 20 or the article 14.
  • the focused energy beam 48 is a laser beam, however, in another implementation the focused energy beam 48 may be a plasma arc or an electron beam.
  • FIG. 3 is a cross-sectioned view of the article 12 shown in FIG. 1 , taken along section A-A.
  • the clad metal layer 42 continues to surround the core material 40 used for the clad wire feedstock 36 (FIG. 2). That is, the clad metal layer 42 of the clad wire feedstock 36 is disposed at a peripheral boundary 52 of each trace 54 deposited by the three-dimensional printer 10 (seen in FIG. 1 ). Accordingly, although the article 12 is composed of two different materials, an outer surface 56 of the article 12 is composed of the material used for the clad metal layer 42 of the clad wire feedstock 36.
  • the clad metal layer 42 is configured to persist after a molten bead of the clad wire feedstock 36 has been deposited by the three-dimensional printer 10. That is, the clad metal layer 42 of the clad wire feedstock 36 does not mix with and stays separate from the core material 40 during the deposition process. In order to ensure that the clad metal layer 42 persists during the deposition process, the clad metal layer 42 includes a melt temperature that is different than the melt temperature of the core material 40 of the clad wire feedstock 36 by at least 10 degrees Celsius.
  • the clad metal layer 42 may also have a wettability or surface tension that is sufficiently different than the core material 40 such that the clad metal layer 42 remains intact after the deposition of the molten bead. That is, the surface tension of the one or more clad metal layers differs from a surface tension of the core material 40 by a threshold amount, where the threshold amount ensures the one or more clad metal layers 42 remain intact after depositing the molten bead.
  • the clad wire feedstock 36 may be fabricated using any number of approaches.
  • the clad wire feedstock 36 starts out as a forming blank that is coated by a shell constructed of the clad metal layer 42.
  • the forming blank is then extruded and drawn down to wire form using drawing dies.
  • the clad metal layer 42 is applied to the outer surface 44 of the core material 40 using any number of techniques such as, but not limited to, electrodeposition, electroless deposition, physical vapor deposition, and plasma coating.
  • the clad metal layer 42 of the clad wire feedstock 36 is constructed of a metal based electrode material.
  • the clad wire feedstock 36 is used to construct the finished article 12 (seen in FIG. 1 ), which is an electrode used in applications such as, but not limited to, batteries, fuel cells, and electroplating.
  • the clad metal layer 42 is constructed of a relatively expensive electrode material such as platinum, and the core material 40 is constructed of a less expensive material such as nickel, copper, stainless steel, or tin. This approach may be used in order to reduce the material costs associated with the article 12 (seen in FIG. 1 ).
  • the clad metal layer 42 is constructed of aluminum, and the core material 40 is constructed of a metal matrix composite such as aluminum-beryllium, or aluminum-silicon carbide.
  • the clad metal layer 42 of the clad wire feedstock 36 is constructed of an electrode material that is relatively dense, such as lead. Because materials such as lead are dense and heavy, it may be challenging to fabricate large articles using only lead, as the article may not be able to support its own weight. Accordingly, the core material 40 of the clad wire feedstock 36 is constructed of a different, stronger material having a lower density such as copper, nickel, or steel.
  • FIG. 4 is another embodiment of the clad wire feedstock 136 where the clad metal layer 142 is constructed of a brazing alloy and the core material 140 is constructed of a material that includes a higher melting temperature than the brazing alloy.
  • the clad wire feedstock 136 is deposited at the melt temperature of the brazing alloy. This allows for higher-performance materials to be deposited using lower processing temperatures and energy requirements.
  • the melt temperature of the core material 140 is at least ten percent higher than the melt temperature of the clad metal layer 142.
  • the clad metal layer 142 is constructed of a brass brazing alloy, which includes a melt temperature of about 450°C, and the core material 40 is constructed of a high strength steel, which includes a melt temperature of about 1450-1510°C.
  • FIG. 5 is yet another embodiment of the clad wire feedstock 236 where the clad metal layer 242 is constructed of a grain boundary inhibitor, and the core material 240 is constructed of a metal that the grain boundary inhibitor controls.
  • the grain boundary inhibitor is configured to inhibit grain growth of the core material 240 once the clad wire feedstock 236 has been deposited, especially around an interface 60 (seen in FIG. 3) between each trace 54 of deposited material.
  • the smaller grain structure results in a core material 240 that has enhanced hardness and increased wear resistance.
  • the core material 240 is constructed of tungsten carbide (WC) with a metal binder such as cobalt (Co), nickel (Ni) or iron (Fe) and the grain growth inhibitors are titanium carbide (TiC), vanadium carbide (VC), molybdenum carbide (M02C) or tantalum carbide (TaC).
  • WC tungsten carbide
  • a metal binder such as cobalt (Co), nickel (Ni) or iron (Fe)
  • the grain growth inhibitors are titanium carbide (TiC), vanadium carbide (VC), molybdenum carbide (M02C) or tantalum carbide (TaC).
  • FIG. 6 is another embodiment of the clad wire feedstock 336 where the clad metal layer 342 is constructed of a material that is relatively ductile so as to be drawn into a wire, while the core material 340 is constructed of a material that is relatively brittle and is not easily drawn into wire form. Accordingly, the core material 340 is constructed of a relatively brittle material that would not typically be used in a wire.
  • the clad metal layer 342 is constructed of aluminum or an aluminum alloy
  • the core material 340 is a metal matrix composite such as aluminum-beryllium, or aluminum-silicon carbide.
  • Another example would be a clad metal layer 342 constructed of a ductile tool steel alloy, and the core material 340 is a high carbon, hard and brittle tool steel.
  • FIG. 7 is yet another embodiment of the clad wire feedstock 436 where the clad metal layer 442 acts as an optical energy absorber that is configured to absorb a specific wavelength of light.
  • the light may be in the ultraviolet, visible, or infrared spectrum.
  • the core material 440 may be constructed of a material that does not effectively absorb the specific wavelength of light.
  • the specific wavelength of light represents the wavelength of the focused energy beam 48 (FIG. 1 ).
  • specific material used for the clad metal layer 442 depends on the specific wavelength used for the focused energy beam 48.
  • the focused energy beam 48 is a laser source having a blue wavelength
  • the core material 440 is aluminum
  • the clad metal layer 442 is copper. It is to be appreciated that copper absorbs substantially more energy from light having a blue wavelength when compared to aluminum.
  • FIG. 8 is yet another embodiment of the clad wire feedstock 536 including the core material 540 and two or more clad metal layers 542 that surround the core material 540.
  • the article 12 (FIG. 1 ) contains a bimetallic microstructure which could enable the material to have a Seebeck coefficient, making the article 12 act as a thermocouple, thermoelectric device, or a bimetallic strip actuator.
  • FIG. 8 illustrates the clad wire feedstock 536 having three layers total, it is to be appreciated that FIG. 8 is merely exemplary in nature and the clad wire feedstock 536 may include any number of layers. For example, in the embodiment as shown in FIG.
  • the clad wire feedstock 636 includes four layers, where the core material 640 is alternated between layers of the clad metal layer 642.
  • the clad metal layer 642 is constructed of a grain boundary inhibitor
  • the core material 640 is constructed of a metal that the grain boundary inhibitor controls.
  • a grain boundary inhibitor is described, it is to be appreciated that other types of materials may be used as well for the clad metal layer 642.
  • the clad metal layer 642 is constructed of a material that is ductile
  • the core material 640 is constructed of a material that is relatively brittle and is not easily drawn into wire form.
  • the disclosed clad wire feedstock provides various technical effects and benefits.
  • the clad wire feedstock allows for an article to include a single type of metal or alloy disposed along its outermost surface, however, the article is constructed of two or more different materials.
  • current filament wires are composed of a single metal or alloy, which results in an article that is homogenous in structure and composition.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Optics & Photonics (AREA)
  • Materials Engineering (AREA)
  • Plasma & Fusion (AREA)
  • Ceramic Engineering (AREA)
  • Structural Engineering (AREA)
  • Composite Materials (AREA)
  • Civil Engineering (AREA)
  • Laser Beam Processing (AREA)

Abstract

L'invention concerne une charge d'alimentation de fil de placage pour un processus de dépôt d'énergie dirigé (DED) et comprend un matériau de coeur définissant une surface externe et une ou plusieurs couches de métal de revêtement qui entourent la surface externe du matériau de coeur.
PCT/US2022/013856 2021-01-29 2022-01-26 Charge d'alimentation de fil plaqué pour la fabrication additive par dépôt d'énergie dirigée WO2022164869A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP22746510.1A EP4274700A1 (fr) 2021-01-29 2022-01-26 Charge d'alimentation de fil plaqué pour la fabrication additive par dépôt d'énergie dirigée
US18/359,422 US20230415267A1 (en) 2021-01-29 2023-07-26 Clad wire feedstock for directed energy deposition additive manufacturing

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US202163143460P 2021-01-29 2021-01-29
US63/143,460 2021-01-29
US202163148999P 2021-02-12 2021-02-12
US63/148,999 2021-02-12

Related Child Applications (1)

Application Number Title Priority Date Filing Date
US18/359,422 Continuation US20230415267A1 (en) 2021-01-29 2023-07-26 Clad wire feedstock for directed energy deposition additive manufacturing

Publications (1)

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WO2022164869A1 true WO2022164869A1 (fr) 2022-08-04

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US (1) US20230415267A1 (fr)
EP (1) EP4274700A1 (fr)
WO (1) WO2022164869A1 (fr)

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20160113556A1 (en) * 2012-10-12 2016-04-28 Dexcom, Inc. Sensors for continuous analyte monitoring, and related methods
US20170326690A1 (en) * 2016-05-16 2017-11-16 Arconic Inc. Multi-component alloy products, and methods of making and using the same
US20180141274A1 (en) * 2016-11-18 2018-05-24 Massachusetts Institute Of Technology Multimaterial 3D-Printing With Functional FIber
US20190168343A1 (en) * 2016-04-12 2019-06-06 Gränges Ab Brazing sheet
US20200370158A1 (en) * 2019-05-20 2020-11-26 Birmingham Technologies, Inc. Method of Fabricating Nano-structures with Engineered Nano-scale Electrospray Depositions

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20160113556A1 (en) * 2012-10-12 2016-04-28 Dexcom, Inc. Sensors for continuous analyte monitoring, and related methods
US20190168343A1 (en) * 2016-04-12 2019-06-06 Gränges Ab Brazing sheet
US20170326690A1 (en) * 2016-05-16 2017-11-16 Arconic Inc. Multi-component alloy products, and methods of making and using the same
US20180141274A1 (en) * 2016-11-18 2018-05-24 Massachusetts Institute Of Technology Multimaterial 3D-Printing With Functional FIber
US20200370158A1 (en) * 2019-05-20 2020-11-26 Birmingham Technologies, Inc. Method of Fabricating Nano-structures with Engineered Nano-scale Electrospray Depositions

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Publication number Publication date
EP4274700A1 (fr) 2023-11-15
US20230415267A1 (en) 2023-12-28

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